Flexco Standard-Duty PTEZ, Heavy-Duty PTEZ Installation, Operation And Maintenance Manual

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Page 1

PTEZ™ Belt Trainer

Installation, Operation

and Maintenance Manual

Standard-Duty PTEZ

www.ﬂexco.com

Heavy-Duty PTEZ

Page 2

PTEZ

™

Belt Trainer

Serial Number: _____________________________________________________________

Purchase Date: ______________________________________________________________

Purchased From: ____________________________________________________________

Installation Date: ____________________________________________________________

Serial number information can be found on the Serial Number Label on the product.

is information will be helpful for any future inquiries or questions about belt cleaner replacement parts, specications or troubleshooting.

2 PTEZ™ Belt Trainer

Page 3

Table of Contents

Section 1 - Important Information ...................................................................................................4

1.1 General Introduction ...........................................................................................................................4

1.2 User Benets .........................................................................................................................................4

1.3 Proper Belt Trainer Selection ..............................................................................................................5

Section 2 - Safety Considerations and Precautions ..........................................................................6

2.1 Stationary Conveyors ...........................................................................................................................6

2.2 Operating Conveyors ...........................................................................................................................6

Section 3 - Pre-Installation Checks and Options ..............................................................................7

3.1 Checklist ................................................................................................................................................7

3.2 Optional Installation Accessories .......................................................................................................8

Section 4 - Installation Instructions ..................................................................................................9

4.1 PTEZ ......................................................................................................................................................9

4.2 HD PTEZ.............................................................................................................................................12

Section 5 - Pre-Operation Checklist and Testing ............................................................................16

5.1 Pre-Op Checklist ................................................................................................................................16

5.2 Test Run the Conveyor ......................................................................................................................16

Section 6 - Maintenance...................................................................................................................17

6.1 New Installation Inspection ..............................................................................................................17

6.2 Routine Visual Inspection .................................................................................................................17

6.3 Routine Physical Inspection .............................................................................................................17

6.4 Roller Replacement Instructions ......................................................................................................18

6.5 Maintenance Log ................................................................................................................................19

6.6 Maintenance Checklist ......................................................................................................................20

Section 7 - Troubleshooting ............................................................................................................21

Section 8 - Specs and CAD Drawings ..............................................................................................22

8.1 CAD Drawing - PTEZ .......................................................................................................................22

8.2 CAD Drawing - HD PTEZ................................................................................................................23

8.3 CAD Drawing - HD PTEZ Underground ......................................................................................24

Section 9 - Replacement Parts .........................................................................................................25

9.1 Replacement Parts List - PTEZ ........................................................................................................25

9.2 Replacement Parts List - HD PTEZ .................................................................................................26

Section 10 - Other Flexco Conveyor Products ................................................................................ 27

Page 4

Section 1 - Important Information

1.1 General Introduction

We at Flexco are very pleased that you have selected a PTEZ™ Belt Trainer for your conveyor system.

is manual will help you to understand the installation, operation and maintenance of this product and assist

you in making it work up to its maximum eciency over its lifetime of service.

It is essential for safe and ecient operation that the information and guidelines presented be properly

understood and implemented. is manual will provide safety precautions, installation instructions, maintenance procedures and troubleshooting tips. In addition, please follow all standard, approved safety guidelines when working on your conveyor.

If, however, you have any questions or problems that are not covered, please visit our web site or contact our

Customer Service Department:

Customer Service: 1-800-541-8028

Visit www.exco.com for other Flexco locations and products.

Please read this manual thoroughly and pass it on to any others who will be directly responsible for installation,

operation and maintenance of this belt trainer. While we have tried to make the installation and service tasks as easy and simple as possible, this product does however require correct installation and regular inspection

and maintenance to maintain top working condition.

1.2 User Benets

Belt mistracking is a common problem that produces various problems, ranging from belt and structure damage

to product spillage and safety issues. By utilizing the PTEZ™, it is possible to correct a belt that is mistracking and causing these problems. Multiple units may be required depending on the length of the mistracking belt.

4 PTEZ™ Belt Trainer

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Section 1 - Important Information

1.3 Proper Belt Trainer Selection

MODEL APPLICATION RANGE

Belt Positioner

™

Return side only, 800 PIW max tension on Small, Medium and Large; 1200 PIW max tension on Extra Large. Also works on reversing belts.

PTEZ

™

Medium-duty belts up to 1600 PIW max tension. Also works on reversing belts. Belt width 18"-48" (450 - 1200mm).

PT Smart

™

Medium-duty belts up to 1600 PIW max tension. Belt width 42" - 84" (050 - 2100mm). Belt thickness 1" (25mm) maximum.

HD PTEZ

™

Medium-duty belts up to 2400 PIW max tension. Belt widths + 9" (225mm) idler. Belt thickness 1" (25mm) maximum. Also works on reversing belts.

PT Pro

™

Medium-duty belts 150 PIW min to 1600 PIW max tension. Belt width 18" - 72" (450 - 1800mm). Also works on reversing belts.

HD PT Pro

™

Heavy-duty belts 300 PIW min to 2400 PIW max tension. Belt width 48" - 96" (1200 - 2400mm). Also works on reversing belts.

PT Max

™

Heavy-duty belts up to 3000 PIW max Generally 3/4" to 1" thick (19mm to 25mm) Belt width 24" - 60" (600 - 1500mm)

HD PT Max

™

Heavy-duty belts up to 6000 PIW max tension. Belt width 54" - 84" (1350 - 2100mm)

Belt Positioner

™

PTEZ

PT Smart

™

Standard

HD PTEZ

PT Pro

PT Max

™

Top Side

™

PT Max Return Side

Conveyor Criteria

Top side mistracking No No No No No No Ye s Yes Ye s

Return side mistracking Yes Yes Yes Ye s Yes Yes Yes Ye s Yes

Reversing Yes Yes Yes No Yes Yes No No No

Belt mistracking to one side Better Better Better Better Better Better Better Better Better

Belt mistracking to both sides Acceptable Better Better Best Better Better Best Best Best

Inconsistent tracking problem Good Better Better Best Better Better Best Best Best

Belt is cupped (heavy) Best ‡ Better ‡ Better ‡ Better Better Better Better Better Better

Belt has edge damage Best Best Best Good Best Best Good Good Good

Ease of Installation Best Better Better Good Good Good Good Good Good

Belt has low running tension (150-300 PIW) Good Good Good Good Good N/A Good N/A N/A

Belt has medium running tension (300-1600 PIW) Better Better Better Better Better Better Best Best Best

Belt has high running tension (1600+ PIW) N/A N/A N/A N/A N/A Best Better Best Best

Approx. "upstream" effect *∆ 50' (15 M) 20' (6 M) 20' (6 M) 20' (6 M) 20' (6 M) 20' (6 M) 50' (15 M) 50' (15 M) 50' (15 M)

Approx. "downstream" effect *∆ 50' (15 M)

‡ Installed on the clean side of the return belt * Typical results; actual results may vary ∆ Disc idlers have the potential to reduce these numbers

Belt

Positioner

™

PTEZ

100' – 120'

(30 – 36 M)

™

Heavy

Duty

PTEZ

100' – 120'

(30 – 36 M)

PT Smart™PT Pro

™

120' – 150'

(36 – 45 M)

100' – 120'

(30 – 36 M)

™

Heavy

Duty

PT Pro

100' – 120'

(30 – 36 M)

™

PT Max

150' – 200'

(45 – 61 M)

™

Heavy

Duty

PT Max

150' – 200'

(45 – 61 M)

™

Super

Duty

PT Max

150' – 200'

(45 – 61 M)

™

Page 6

Section 2 - Safety Considerations and Precautions

Before installing and operating the PTEZ™ Belt Trainer, it is important to review and understand the following safety information.

ere are setup, maintenance and operational activities involving both stationary and operating conveyors. Each case has a safety protocol.

2.1 Stationary Conveyors

e following activities are performed on stationary conveyors:

• Installation • Idler replacement

• Cleaning • Repairs

DANGER

It is imperative that OSHA/MSHA Lockout/Tagout (LOTO) regulations, 29 CFR 1910.147, be followed before undertaking the preceding activities. Failure to use LOTO exposes workers to uncontrolled behavior of the belt trainer caused by movement of the conveyor belt or belt trainer. Severe injury or death can result.

Before working:

• Lockout/Tagout the conveyor power source

• Clear the conveyor area where work is to take place

WARNING

Use Personal Protective Equipment (PPE):

• Safety eyewear

• Hardhats

• Safety footwear

Close quarters and heavy components create a worksite that compromises a worker’s eyes, feet and skull. PPE must be worn to control the foreseeable hazards associated with conveyor belt components. Serious injuries can be avoided.

2.2 Operating Conveyors

ere are two routine tasks that must be performed while the conveyor is running:

• Inspection of belt trainer performance

• Dynamic troubleshooting

DANGER

WARNING

Every belt conveyor is an in-running nip hazard. Never touch or prod an operating belt trainer. Conveyor hazards cause instantaneous amputation and entrapment.

WARNING

Conveyors contain moving hazards. Stay as far from the trainer as practical and use safety eyewear and headgear.

6 PTEZ™ Belt Trainer

Never adjust anything on an operating belt trainer. Flailing hardware can cause serious injury or death.

Page 7

Section 3 - Pre-installation Checks and Options

3.1 Checklist

• Check the model and size of the belt trainer. Is it the right one for your beltline?

• Check the PTEZ™ to be sure all the parts are included in the shipment.

– Trainer

–

Mounting hardware

– Instruction kit

• Find the information packet in the shipment

• Review the “Tools Needed” section on the front of the installation instructions.

• Prepare the conveyor site:

– Identify the point(s) of mistracking, expecting 100'- 120' (30-37 M) of downstream inuence.

– Position the unit 20' (6.1 M) aer the start of the mistracking.

– Identify an opening of at least 9" (225mm) for Standard Duty, 10.5" (265mm) for Heavy Duty if possible to

avoid interference with roller during installation.

– Remove old tracking devices.

– If the conveyor has disc idlers, replace one idler before and one idler aer the location where the trainer

will be installed with a standard idler.

– If the conveyor has V-return idlers, replace one idler before and aer where the trainer will be located with

a standard at idler.

Page 8

Section 3 - Pre-Installation Checks and Options (cont.)

3.2 Optional Installation Accessories

Optional tools can make the installation of the PTEZ™ Belt Trainer easier and faster.

Flex-Lifter™ Conveyor Belt Lifter

Description

Medium Flex-Lifter 36" - 60" (900 - 1500mm) FL-M 76469 Large Flex-Lifter 48" - 72" (1200 - 1800mm) FL-L 76470 XL Flex-Lifter 72" - 96" (1800-2400mm) FL-XL 76983

Ordering

Number

Flex-Lier™ Conveyor Belt Lier

e Flexco Flex-Lier makes the job of liing the conveyor belt easy and safe. Using two Flex-Liers, the belt can be quickly lied out of the way to install the PTEZ™. e Flex-Lier has the highest safe li rating available at 4000 lbs (1810 kg). And it’s versatile. It can also be used to li topside or return side belt for splicing, roller replacement or other maintenance jobs. Available in three sizes: Medium for belt widths 36" - 60" (900 - 1500mm), Large for belt widths 48" - 72" (1200 - 1800mm), and XL for belt widths 72" - 96" (1800 - 2400mm).

Item

Code

8 PTEZ™ Belt Trainer

Page 9

Section 4 - Installation Instructions - PTEZ

™

4.1 PTEZ

™

Roller

Mounting Bracket

Dust Cover

Main Shaft

Bracket

Physically lock out and tag the conveyor at the power source

before you begin belt trainer installation.

Main Shaft

End Cap

CAUTION: Components may be heavy. Use safety-approved liing procedures.

Before You Begin:

• A serial number label is located in the instruction packet. Following installation, please locate space on or near the PTEZ to apply this label. Please use this number in any correspondence.

• Use the necessary mechanical liing equipment (crane, come-alongs, etc.) for safe installation.

• e trainer should not be positioned closer than 20 feet (6M) from the tail pulley, take-up pulleys, or head pulley.

• Follow all safety precautions when using a cutting torch.

Conveyor Site Preparation:

• Identify the point(s) of mistracking, expecting 100'- 120' (30-37 M)

of downstream inuence.

• Position the unit 20' (6 M) aer the start of the mistracking.

• Identify an opening of at least 9" (225mm).

• Remove any existing tracking devices that fall in the estimated

tracking range of the PTEZ as multiple dierent tracking devices may reduce or prevent the PTEZ from tracking as intended.

Tools Needed:

• Tape Measure

• (2) 3/4" Wrenches (19mm)

• Medium or Large Adjustable Wrench

• Cutting Torch/Welder

• (2) Come-Alongs (3/4 Ton Minimum)

• Any necessary equipment for moving and liing heavy components

• Straightedge or Level

• Marking Pen

9" (225mm)

Page 10

Section 4 - Installation Instructions - PTEZ

4.1 PTEZ

PTEZ Preparation and Installation:

1. Identify location for PTEZ and mount one bracket.

STRUCTURE

BELT

3" (75mm)

Fig. 1

BELT

Lift Belt 3" (75mm)

Fig. 2

1-5/8"

(41mm)

a. For push-up installation, use a straightedge to push up

against the belt to remove the slack and make a mark on the bracket for the bottom of the belt. From that mark, measure down 3" (75mm) and make a second mark (Fig. 1). e second mark is where the center of the pole should line up in Step 6.

b. For push-down or clean-side installation, use a

straightedge to push down against the belt to remove the slack and make a mark on the bracket for the top of the belt. From that mark, measure up 3" and make a second mark. e second mark is where the center of the pole should line up in Step 6.

2. Li the belt approximately 3" (76mm) where the trainer will be installed. Remove existing idler (if applicable) (Fig. 2). NOTE: If the conveyor has disc idlers, replace one idler with a standard idler before and aer the location where the trainer will be installed.

™

Fig. 3

Fig. 4

(76mm)

Equal Distance

Main Shaft Bracket

3. Position mounting brackets. May be mounted to existing idler hole patterns. Overall range of adjustment on brackets is 1-5/8" (41mm) above the top ange or 3 (76mm) below the top ange (Fig. 3).

4. Square the mounting brackets. Measure from a xed location on both sides to ensure alignment (Fig. 4).

5. Slide on the main sha brackets. Finger-tighten bolts for further adjustment later (Fig. 5).

Fig. 5

10 PTEZ™ Belt Trainer

Finger-tighten bolt

Page 11

Section 4 - Installation Instructions - PTEZ

™

4.1 PTEZ

6. Li the roller and main sha bracket assembly. Be sure to use safe and secure liing procedures to li the PTEZ into position. Ensure the arrows on main sha label point up or down towards the belt (Fig. 6a).Align center of sha with mark on mounting bracket (from Step 1) and nger-tighten bolts between the mounting bracket and main sha bracket (Fig. 6b).

STRUCTURE

BELT

Align center of shaft with mark

Finger-tighten bolts

Fig. 6a

Fig. 7

Arrows must point to belt

Equal

Belt

Roller

INCORRECT - raise roller

Belt

Roller

Fig. 6b

7. Ensure main sha is centered on main sha

brackets (equal length showing on both sides of

roller) (Fig. 7).

8. Lower the belt onto the roller. Ensure belt completely contacts roller. Raise extending brackets one hole if there is not good contact (Fig. 8). Belt should be pushed up or down approximately 1/2" to 1" (1225mm) from normal running height. If there is still a gap between the PTEZ and the belt, adjustments may be made in 1/2" (12mm) increments until the gap disappears. NOTE: If gap persists consider push-down installation.

Fig. 8

CORRECT

9. Tighten all bolts, install end caps on main sha, and

proceed to pre-op checklist on page 12.

Page 12

Section 4 - Installation Instructions - PTEZ

™

4.2 HD PTEZ

Physically lock out and tag the conveyor at the power source

™

Roller

Dust Cover

Main Shaft

Mounting Bracket

Main Shaft

Bracket

Main Shaft

End Cap

before you begin belt trainer installation.

CAUTION: Components may be heavy. Use safety-approved liing procedures.

Before You Begin:

• A serial number label is located in the instruction packet. Following installation, please locate space on or near the HD PTEZ to apply this label. Please use this number in any correspondence.

• Use the necessary mechanical liing equipment (crane, comealongs, etc.) for safe installation.

• e trainer should not be positioned closer than 20 feet (6M) from the tail pulley, take-up pulleys, or head pulley.

• Follow all safety precautions when using a cutting torch.

Conveyor Site Preparation:

• Identify the point(s) of mistracking, expecting 100'- 120' (30-37 M

of downstream inuence.

• Position the unit 20' (6 M) aer the start of the mistracking.

• Identify an opening of at least 12" (305mm).

• Remove any existing tracking devices that fall in the estimated

tracking range of the HD PTEZ as multiple dierent tracking devices may reduce or prevent the HD PTEZ from tracking as intended.

Tools Needed:

• Tape Measure

• (2) 3/4" Wrenches (19mm)

• Medium or Large Adjustable Wrench

• Cutting Torch/Welder

• (2) Come-Alongs (3/4 Ton Minimum)

• Any necessary equipment for moving and liing heavy components

• Straightedge or Level

• Marking Pen

12" (305mm)

15" (381mm)

12 PTEZ™ Belt Trainer

Page 13

Section 4 - Installation Instructions - PTEZ

™

4.2 HD PTEZ

™

PTEZ Preparation and Installation:

For Underground J-bolt or wire rope mounting, see page 15.

STRUCTURE

BELT

3.5" (90mm)

Fig. 1

BELT

Lift Belt 5" (125mm)

1. Identify location for HD PTEZ and mount one bracket. a. For push-up installation, use a straightedge to push up

against the belt to remove the slack and make a mark on the bracket for the bottom of the belt. From that mark, measure down 3.5" (90mm) and make a second mark (Fig. 1). e second mark is where the center of the pole should line up in Step 6.

b. For push-down or clean-side installation, use the

weight of the roller to deect the belt and remove cupping. Mount brackets to structure and check position of mounting holes. Push unit down 1/2" (50mm) more and bolt in place. Conrm no daylight.

2. Li the belt approximately 5" (125mm) where the trainer will be installed. Remove existing idler (if applicable) (Fig. 2). NOTE: If the conveyor has disc idlers, replace one idler with a standard idler before and aer the location where the trainer will be installed.

Fig. 2

Fig. 3

1-1/4"

(32mm)

8-3/4"

(222mm)

Equal Distance

3. Position mounting brackets. May be mounted to existing idler hole patterns. Overall range of adjustment on brackets is 1-1/4" (32mm) above the top ange or 8-3/4" (222mm) below the top ange (Fig. 3).

4. Square the mounting brackets. Measure from a xed location on both sides to ensure alignment (Fig. 4).

5. Slide on the main sha brackets. Finger-tighten bolts for further adjustment later (Fig. 5).

Main Shaft Bracket

Fig. 4

Fig. 5

Finger-tighten bolt

Page 14

Section 4 - Installation Instructions - PTEZ

™

4.2 HD PTEZ

™

6. Li the roller and main sha bracket assembly. Be sure to use safe and secure liing procedures to li the HD PTEZ into position. Ensure the arrows on main sha label point up or down towards the belt (Fig. 6a).Align center of sha with mark on mounting bracket (from Step 1) and nger-tighten bolts between the mounting bracket and main sha bracket (Fig. 6b).

STRUCTURE

Fig. 6a

BELT

Finger-tighten

bolts

Arrows must point to belt

Align center of shaft with mark

Fig. 7

Equal

Belt

Roller

INCORRECT - raise roller

Belt

Roller

Fig. 6b

7. Ensure main sha is centered on main sha

brackets (equal length showing on both sides of

roller) (Fig. 7).

8. Lower the belt onto the roller. Ensure belt completely contacts roller. Raise extending brackets one hole if there is not good contact (Fig. 8). Belt should be pushed up or down approximately 1/2" to 1" (1225mm) from normal running height. If there is still a gap between the HD PTEZ and the belt, adjustments may be made in 1/2" (12mm) increments until the gap disappears. NOTE: If gap persists consider push-down installation.

Fig. 8

14 PTEZ™ Belt Trainer

CORRECT

9. Tighten all bolts, install end caps on main sha, and

proceed to pre-op checklist on page 12.

Page 15

Section 4 - Installation Instructions - PTEZ

™

4.2 HD PTEZ

™

Underground Mounting Instructions

Parts shown below included with PTEZHD-UG items.

10. To attach mounting brackets to 4" or 5" channel structure, use included J-bolt plates as shown (customer

supplied J-bolt). (Fig. 9).

Fig. 6b

11. To mount to wire rope structure, use included U-bolt kit and position as shown. (Fig. 10).

Fig. 6b

Page 16

Section 5 - Pre-Operation Checklist and Testing

5.1 Pre-Op Checklist

• Recheck that all fasteners are tight

• Apply all supplied labels

• Be sure that all installation materials and tools have been removed from the belt and conveyor area

• Reconrm the arrows on the main tube point up or down towards the belt

5.2 Test Run the Conveyor

• Run the conveyor for at least 15 minutes and conrm the belt is tracking properly.

• If belt is still mistracking too far to one side, height adjustments may be made in 1/2" (12mm) increments

until air gap disappears. NOTE: Belt wrap around PTEZ should not exceed 10°

• NOTE: If conveyor has disc idlers, the belt may not get the full downstream tracking eect.

16 PTEZ™ Belt Trainer

Page 17

Section 6 - Maintenance

Flexco belt trainers are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the trainer is installed a regular maintenance program should be set up. is program will ensure that the trainer operates at optimal eciency, and problems can be identied and xed before any damage is done to the belt, the trainer, other conveyor components, or structure.

All safety procedures for inspection of equipment (stationary or operating) must be observed. e PTEZ™ is in direct contact with the moving belt. Only visual observations can be made while the belt is running. Service tasks can be done only with the conveyor stopped and by observing the correct lockout/tagout procedures.

6.1 New Installation Inspection

Aer the PTEZ has run for 15 minutes a visual inspection should be made to ensure the trainer is performing properly. Make adjustments as needed.

6.2 Routine Visual Inspection (every 2-4 weeks)

A visual inspection of the PTEZ can determine:

• If the belt is tracking as required

• If the trainer is moving freely

• If the trainer is free of material and rolling properly

• If there is damage to the sha or other components

If any of the above conditions exist, a determination should be made on when the conveyor can be stopped for trainer maintenance.

6.3 Routine Physical Inspection (every 6-8 weeks)

When the conveyor is not in operation and properly locked and tagged out, a physical inspection of the trainer to perform the following tasks:

• Clean material buildup o the trainer and components.

• Pivot unit to ensure full and easy movement.

• Closely inspect complete unit for damage.

• Inspect all fasteners for tightness and wear. Tighten or replace if needed.

• When maintenance tasks are completed, test run the conveyor to ensure the trainer is performing

prop e r l y.

Page 18

Section 6 - Maintenance

6.4 Roller Replacement Instructions

Tapered Idler

Physically lock out and tag the conveyor at the power source

before you begin cleaner installation.

CAUTION: Components may be heavy. Use safety-approved liing procedures.

1. Remove tension from belt. Use a Flex-Lier or other appropriate liing equipment to li the belt approx. 3"

(75mm) o the trainer.

2. Mark the mounting bracket above or below the main sha bracket for reference when installing the new roller to ensure replaement roller is installed at the same height.

3. Remove roller.

4. Install new roller. Conrm roller turns smoothly.

5. Lower the belt. Ensure belt completely contacts roller. Tighten all bolts.

18 PTEZ™ Belt Trainer

Page 19